Least pressure drop in the system to reduce operating costs. Maximum pressure drop between the compressor and farthest end of compressed air consumption should be around 0.3 bar

Velocities between 6-10m/s in air mains; this will limit the DP & thus energy consumption and also allow moisture to precipitate

Minimum bends & joints (long radius bends to be used)

Arrangement for draining of moisture at regular intervals, slope provision

Minimum expanders/reducers

Leak proof joints, proper piping supports

Gauges to be provided at different locations to monitor the system pressure & temperature.

Compressor Cooling system:

Cooling plays important role in energy efficiency, two types are:

Air cooled – In-efficient, preferred only for low capacity compressors

Water cooled – Efficient, used for high capacity compressors

Water is circulated in a jacket around the cylinders to remove the heat resulting from compression & friction due to sliding of pistons. Water is also required for the inter/after coolers and lube-oil coolers.

CW consumption for inter/after coolers can be estimated based on compression ratio per stage assuming an adiabatic efficiency.

Generally, per thumb rule,

Compressed air plant layout and distribution:

Plant layout:

Centralized layout

All compressors installed in single house, cost effectiveness as maximum plant space utilization